Advanced Machine Design Course Introduction PDF

Advanced Machine Design Course Introduction AY 2024-25 Aim of the course 2  The aim of the course is to provide the basic knowledge to design the fundamental machine elements involved in transport field. The course introduces basics and fu...

Advanced Machine Design Course Introduction AY 2024-25 Aim of the course 2  The aim of the course is to provide the basic knowledge to design the fundamental machine elements involved in transport field. The course introduces basics and fundamentals of design, strength analysis and lifetime prediction of mechanical components. Mechanical components will be described highlighting concepts and methodologies for an effective structural design. Mechanical behaviour of materials will constitute one of the main topic of the course, focusing on multi-axial static & fatigue analyses, fracture mechanics and fatigue crack propagation. Theory and methods will be applied to significant mechanical cases during the course. To design means to conceive and create a structure, a vehicle, a machine, an airplane … which must work properly according with its strength (main purpose of the course), but this is not enough. A good design must comply with several requirements: Function Safety Reliability Optimized Weight and Size Costs Environment, Recyclable materials Advanced Machine Design – Introduction Lecture plan 3 Topics of the lectures: Introduction Design criteria Statically indeterminate systems and superposition method (force method) Finite Element Method (FEM) for structural analysis Elasto-plastic behaviour of materials Stress & strain analysis in plastic field - Notched members and bending Axisymmetrical components: disks and cylinders Fatigue behaviour of materials Fracture mechanics Strength assessment for different failure conditions (static, fatigue, crack propagation, etc.) Advanced Machine Design – Introduction Practice plan 4 Topics of the practices: FE analysis of mechanical components Structure of a bridge crane Shaft of a railway axle: 1: Calculation of the reactions and internal forces diagrams 2: Shrink fit 3: Static and fatigue assessment Hydraulic cylinder/pressure vessel: 1: Stress analysis with FEA 2: Experimental test and comparison SHM test bench: 1: Analytical model and FEM 2: Experimental tests 4: Structural Health Monitoring and machine learning Bolted joints General exercises Advanced Machine Design – Introduction Course Organisation 5 Marco Giglio, main lecturer [email protected] +39 02.2399.8234 Luca Lomazzi, practical classes, lab classes, FE lessons [email protected] +39 02.2399.8491 Advanced Machine Design – Introduction Course Organisation 6 Lessons Monday, 10.30 - 12 (BL.27.0.2, 2 hours) Tuesday, 8.30 - 10 (B8.2.1, 2 hours) - Theoretical treatment of the topics (presentations) and some numerical examples Practical classes Wednesday, 8.30 - 12 (B2.1.1) - Analysis of mechanical components and systems with analytical and numerical approaches. Exercises and numerical applications. Lab classes Wednesday, 8,30 - 12 (Building B13 lab), 16 April 2025 - SHM test bench : testing and SHM application Advanced Machine Design – Introduction Course Organisation 7 Tutoring Tentative dates (after the end of the course): - 9 June, 9.15-13.15, TBC - 10 June, 9.15-13.15, TBC Exercises and numerical applications, exam simulation. Advanced Machine Design – Introduction Course Tools and Organization 8 Classroom explanation of the topics (lectures) followed by practical development (practices) and experimental labs Matlab can be used for analytical/numerical development FE code: Abaqus Advanced Machine Design – Introduction Experimental labs and practices 9 EXPERIMENTAL LAB: Measurement of strains by means of strain gages on a beam structure Test on different undamaged and damaged configurations Structural Health Monitoring applications Advanced Machine Design – Introduction Exam 10 Two Compulsory written tests Written Test 1: Exercises and theoretical questions (duration ≈ 2.5-3 hours) No books or notes are allowed (all the necessary material will be provided along with the text of the exam) A compendium of formulae is available online and it is allowed for the exam Minimum mark to continue the exam: 15/30 Maximum mark: 25/30 Written Test 2: Theoretical questions, short exercises (multiple choice answers) Different questions on general theory and the topic of the practices, small exercises Minimum mark to continue the exam: 3/30 Range of possible mark: +8/-4 points “30 cum laude” can be obtained only if the Written Test 1 has a 25/30 score and Written Test 2 has a 8/30 score Advanced Machine Design – Introduction Books and notes 11 Copies of Power point slides will be published on the official website of the course, WeBeep (https://webeep.polimi.it) Main references:  N. Dowling, Mechanical Behavior of Materials, Pearson International Edition, 2013  A.C. Ugural, S.K. Fenster, Advanced Strength and Applied Elasticity, Fifth Edition, Prentice Hall, 2012  Cook, Robert D., Finite element modeling for stress analysis, Wiley, 1995 Advanced Machine Design – Introduction  Preliminary planning of the course 1/2 12 Day of the Week Date Room ID_lesson Lesson Teacher week Monday 17/02/2025 10-12, Room BL.27.0.2 L1 Introduction Marco Giglio 1 Tuesday 18/02/2025 8-10, Room B8.2.1 L2 1 - Design criteria Marco Giglio Wednesday 19/02/2025 8-12, Room B2.1.1 P1 P1 - Exercises: static assessment of bolted joints Luca Lomazzi Monday 24/02/2025 10-12, Room BL.27.0.2 L3 2 - Force method 1/2 Marco Giglio 2 Tuesday 25/02/2025 8-10, Room B8.2.1 L4 2 - Force method 2/2 Marco Giglio P2 - Exercises: bridge Crane (general exercises on Force Wednesday 26/02/2025 8-12, Room B2.1.1 P2 Luca Lomazzi method, internal forces, beam dispacements) Monday 03/03/2025 10-12, Room BL.27.0.2 L5 FEM 1/4 Luca Lomazzi 3 Tuesday 04/03/2025 8-10, Room B8.2.1 L6 Force method exercises Marco Giglio Wednesday 05/03/2025 Vacation/Lesson suspended Monday 10/03/2025 10-12, Room BL.27.0.2 L7 FEM 2/4 Luca Lomazzi 4 Tuesday 11/03/2025 8-10, Room B8.2.1 L8 FEM 3/4 Luca Lomazzi Wednesday 12/03/2025 8-12, Room B2.1.1 P3 P3 - Exercises: force method Luca Lomazzi Monday 17/03/2025 10-12, Room BL.27.0.2 L9 FEM 4/4 Luca Lomazzi 5 Tuesday 18/03/2025 8-10, Room B8.2.1 L10 3 - Axisymmetric elastic problems - Rotating disks Marco Giglio Wednesday 19/03/2025 8-12, Room B2.1.1 P4 P4 - FEM: bridge crane and shell with hole Luca Lomazzi Monday 24/03/2025 10-12, Room BL.27.0.2 L11 3 - Axisymmetric elastic problems - Rotating cylinders Marco Giglio 6 Tuesday 25/03/2025 8-10, Room B8.2.1 L12 Axisymmetric elastic problems: applications Marco Giglio Wednesday 26/03/2025 8-12, Room B2.1.1 P5 P5 - Exercises and FEM: Shrink fit and shaft-hub connections Luca Lomazzi Monday 31/03/2025 10-12, Room BL.27.0.2 L13 4 - Stress-strain analysis in plastic field - Notched members Marco Giglio 7 Tuesday 01/04/2025 8-10, Room B8.2.1 L14 5 - Stress-strain analysis in plastic field - Plasticity in bending Marco Giglio Wednesday 02/04/2025 8-12, Room B2.1.1 P6 P6 - FEM: hydraulic cylinders Luca Lomazzi Advanced Machine Design – Introduction Preliminary planning of the course 2/2 13 Day of the Week Date Room ID_lesson Lesson Teacher week Monday 07/04/2025 Vacation/Lesson suspended 8 Tuesday 08/04/2025 Vacation/Lesson suspended Wednesday 09/04/2025 Vacation/Lesson suspended Monday 14/04/2025 10-12, Room BL.27.0.2 L15 6 - Fatigue of metallic materials-1 Marco Giglio 9 Tuesday 15/04/2025 8-10, Room B8.2.1 L16 Introduction to SHM Claudio Sbarufatti P7 LAB - Data acquisition on SHM test rig - Machine learning for Wednesday 16/04/2025 8-12, Room B2.1.1 P7 Luca Lomazzi SHM Monday 21/04/2025 Vacation/Lesson suspended 10 Tuesday 22/04/2025 Vacation/Lesson suspended Wednesday 23/04/2025 8-12, Room B2.1.1 P8 P8 - Exercises: stress-state in complex scenarios, plasticity Luca Lomazzi Monday 28/04/2025 10-12, Room BL.27.0.2 L17 6 - Fatigue of metallic materials-2 Marco Giglio 11 Tuesday 29/04/2025 10-12, Room BL.27.0.2 L18 6 - Fatigue design - Multiaxial criteria Marco Giglio P9 - Exercises: introduction to fatigue - Introduction to railway Wednesday 30/04/2025 8-12, Room B2.1.1 P9 Luca Lomazzi axle design Monday 05/05/2025 10-12, Room BL.27.0.2 L19 6 - Fatigue design - Variable amplitude assessment Marco Giglio 12 Tuesday 06/05/2025 8-10, Room B8.2.1 L20 Fatigue design applications Marco Giglio Wednesday 07/05/2025 8-12, Room B2.1.1 P10 P10 - Exercises and FEM: railway axle Luca Lomazzi Monday 12/05/2025 10-12, Room BL.27.0.2 L21 7 - Fracture mechanics - Static assessment 1 Marco Giglio 13 Tuesday 13/05/2025 8-10, Room B8.2.1 L22 7 - Fracture mechanics - Static assessment 2 Marco Giglio P11 - Exercises on pressure vessels, fatigue and fracture Wednesday 14/05/2025 8-12, Room B2.1.1 P12 Luca Lomazzi mechanics PART 1 Monday 19/05/2025 10-12, Room BL.27.0.2 L23 7 - Crack propagation Marco Giglio 14 Tuesday 20/05/2025 8-10, Room B8.2.1 L24 Fracture Mechanics applications Marco Giglio P12 - Exercises on pressure vessels, fatigue and fracture Wednesday 21/05/2025 8-12, Room B2.1.1 P12 Luca Lomazzi mechanics PART 2 Monday 26/05/2025 10-12, Room BL.27.0.2 L25 Fatigue and Fracture mechanics application - Comet case study Andrea Manes Machine Design applications, Track Advanced Mechanical Research group SIGMALab 15 Tuesday 27/05/2025 8-10, Room B8.2.1 L26 Design, Thesis available (http://www.giglio.faculty.polimi.it/) P13 - Exercises on pressure vessels, fatigue and fracture Wednesday 28/05/2025 8-12, Room B2.1.1 P13 Luca Lomazzi mechanics PART 3 Advanced Machine Design – Introduction